GESTRA. GESTRA Steam Systems ZK 313 ASME. Installation Instructions Control Valve ZK 313 ASME

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1 GESTRA GESTRA Steam Systems ZK 313 ASME Installation Instructions Control Valve ZK 313 ASME 1

2 Contents Important Notes Usage for the intended purpose... 4 Safety note... 4 Danger... 4 Attention... 5 Explanatory Notes Scope of supply... 6 System description... 6 Function... 7 Design... 7 Technical Data Pressure / temperature ratings for ZK 313 ASME (valve without connections)... 8 Service pressure for Class 2500 in [bar] to ASME B Service pressure for Class 2500 in [psig] to ASME B Admissible differential pressure... 8 Materials... 8 kv s values... 9 Weight... 9 Corrosion resistance... 9 Sizing... 9 Name plate / marking... 9 Dimensions... 10/11 Capacity chart ZK 313 ASME, cold water Capacity chart ZK 313 ASME, hot water ts-5k...13 Design Design ZK 313 ASME, straight-through valve...14 Design ZK 313 ASME, angle valve Key Page Installation ZK 313 ASME Attention Valve with socket-weld ends Valve with butt-weld ends Heat treatment of welds Pickling and rinsing Attention

3 Contents continued Commissioning Page ZK 313 ASME Attention Operation ZK 313 ASME Attention Maintenance ZK 313 ASME Decommissioning Danger Disposal

4 Important Notes Usage for the intended purpose ZK 313 ASME The control valve ZK 313 ASME is intended solely for cutting off and/or regulating the flow of fluids consisting of water, steam, or steam condensate. Its use is permissible only within the allowable limits of pressure and temperature and only if the chemical and corrosive influences on the pressure equipment are taken into account. Before installation and operation, a check must be performed to ascertain that the valve is resistant to the medium in the operational conditions that will exist. To ensure safe operation of the valve ZK 313 ASME only actuators named and specified by GESTRA may be installed on the control valve. Safety note The control valve must only be installed by qualified staff. Qualified staff are persons who are familiar with the procedures for installation and commissioning of the product, and who have qualifications appropriate for their work, for example staff who have received the following: Training as specialists. Training or instruction in the use of appropriate safety procedures in accordance with regulations concerning safety standards. Training or instruction in first aid and in accident prevention regulations. Danger The valve is under pressure during operation. When loosening flanged connections, sealing plugs or stuffing boxes, hot water and/or steam may escape. Installation and maintenance work should only be carried out when the system is depressurised: isolate the valve from both upstream and downstream pressure. Make sure that the pressure in control lines is zero. The valve is hot during operation. This presents the danger of severe burns to hands and arms. Installation and maintenance work should only be carried out when the system is cold. Risk of severe burns and scalding over the entire body! Before carrying out maintenance work on the valve or loosening flanged connections, stuffing boxes or sealing plugs make sure that all connected lines are depressurised (0 bar) and cooled down to room temperature (20 C). Danger of bruising: During operation moving internals can cause contusions to hands. Do not touch the valve during operation! The control valves ZK 313 ASME are remote controlled and can open and close very abruptly. Sharp edges on internal parts present a danger of cuts to hands. Always wear industrial gloves for installation and maintenance work. Danger of eye injuries: Always wear safety goggles when mounting or checking the equipment. 4

5 Important Notes continued Attention The name plate states the technical features of the equipment. A valve without such a name plate must neither be commissioning nor operated. 5

6 Explanatory Notes Scope of supply ZK 313 ASME 1 High-pressure control valve ZK 313 ASME according to specification 1 Actuator according to specification 1 Parts list with drawing of components 1 Inspection certificate detailing equipment-specific technical data 1 Declaration of conformity (when valve is used within EU) 1 Declaration of manufacturer (when valve is used within EU) 1 Installation manual Description Control valve for reducing high differential pressures. Application in industrial plants and power stations as Injection control valve Warm-up valve Drain valve Continuous blowdown valve Feedwater control valve Leak-off valve Steam control valve The pressure drop is decreased in the radial stage nozzle in several steps in order to reduce the flow velocity especially in the orifice, thus leading to a considerable reduction in wear and noise ( 85 db (A)). 6

7 Explanatory Notes continued Function All pressure parts of the ZK 313 are forged. Internals (incl. seat) are easily exchangeable, even after a long period of use. The radial stage nozzle ZK combines the function of a control valve with a conventional shut-off valve and guarantees maximum wear protection and absolutely tight shut-off. The radial stage nozzle ZK consists of several sleeves nesting within one another, containing radial orifices drilled in them. The orifices are shifted relative to one another, thus forming a large number of throttling points in parallel, with turbulence chambers (expansion chambers) in between, where potential energy in the form of pressure is converted into kinetic energy in the form of flow. Due to the successive expansion in the flash chambers the pressure drop at the seat of the valve plug is considerably reduced. The flowrate through the radial stage nozzle is determined by the valve plug. According to its position the individual stage nozzles are either partially or completely set free, thus producing different flowrates. The valve plug and the seat form the shut-off unit of the radial stage nozzle. The control valve ZK 313 is also equipped with a dual (tandem) shut-off. At the moment of closing and at the beginning of opening the flow velocity at the valve seat is zero, which means that wire drawing and wear on the seating surfaces is prevented. The lift difference between the control piston and the leading valve plug is balanced out by disc springs. Depending on the pressure drop to be coped with different stage nozzles and valve plugs are available. Due to the special design of the radial stage nozzle ZK the noise level is reduced to a minimum. As a result of the expansion through a multitude of individual nozzles, the noise emitted by the control valve is below 85 db (A) within the control range of the valve. The valve body is available as straight-through or angle version, sizes 1" to 3". The valve can be easily fitted with a pneumatic actuator. Leak rates in accordance with EN Tightness better than ANSI Class V. Design ZK 313 ASME-D/20: Straight-through valve with butt-weld ends. Fig. 6 ZK 313 ASME-E/20: Angle valve with butt-weld ends. Fig. 7 7

8 Technical Data Pressure / Temperature Ratings ZK 313 ASME Service pressure for Class 2500 in [bar] to ASME B16.34 Service pressure for Class 2500 in [psig] to ASME B16.34 Nuts A Temperature in [ C] Standard Class F1 F22 F91 F1 Limited Class F22 *) Service temperatures above 570 C / 1050 F increase wear on the nozzle insert of the control valve. Admissible differential pressure 1 ) 2 ) F *) *) *) PMX 1 stage [bar] / [psig] 40 / 580 PMX 3 stages [bar] / [psig] 300 / 4351 PMX 3 stages with additional nozzle [bar] / [psig] 370 / ) Observe pressure and temperature ratings of the equipment 2 ) Inlet pressure minus outlet pressure Temperature in [ F] Standard Class F1 F22 F91 F1 Limited Class F22 F , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , *) 1, , , , *) , , , *) , , , Materials Body A 182 F / A 182 F22 Upper body part / A 182 F91 Bolts A 193 B / A 182 F91 8

9 Technical Data continued kv s values Size 1" to 3" 1" to 3" Characteristic linear/ equal-percentage linear/ equal-percentage 1" to 3" linear p max. [bar] [psi] (1.2) 1.5 (1.7) 2.3 (2.7) kv s (Cv) 3.6 (4.2) 20 (23.1) 5.5 (6.4) 4.5 (5.3) 8 (9.4) 7 (8.2) 11 (12.7) 9.5 (11) 13 (15) 10.5 (12.1) Valve lift [mm] Weight ZK 313 ASME PB 1502 PB 3002 PB 1502 with manual actuator PB3002 with manual actuator Weight [kg] Weight [lb] Corrosion resistance If the valve is used for its intended purpose, its safety is not impaired by corrosion. Sizing The valve body must not be subjected to sharp increases in pressure. The dimensional allowances for corrosion reflect the latest state of technology. Name plate / marking According to EN 19 and MSS-SP 25 the type and design are specified on the valve body and the name plate: designation ZK 313 ASME: Version without actuator ZK 313 ASME: Version with actuator Marking according to ATEX: II 2G/D c X 4 Stamp on name plate, e. g. indicates term and year of production (example: 4 th quarter 2005) 05 Equipment designation ASME Class Nominal size Wall thickness of tube Pressure / temperature ratings CE marking according to PED Fig. 1 Production date Internals Body material 9

10 Technical Data continued Dimensions 548 ½" BSP 82 d Valve lift Fig. 2 ZK 313 ASME-D/20 with actuator PB

11 Technical Data continued Dimensions 548 ½" BSP 82 d Valve lift Fig. 3 ZK 313 ASME-E/20 with actuator PB

12 Technical Data continued Capacity Charts ZK 313 ASME, cold water [gal/h] [m 3 /h] Cold water capacity [bar] [psi] Differential pressure, assuming discharge to atmospheric pressure (at higher back pressures use correction factor) Fig. 4 Curve kv s value Curve C v value

13 Technical Data continued Capacity Charts ZK 313 ASME, hot water ts-5k [lb/h] [t/h] Hot water capacity [bar] [psi] Differential pressure, assuming discharge to atmospheric pressure (at higher back pressures use correction factor) Fig. 5 Curve kv s value Curve C v value

14 Design ZK 313 ASME, straight-through valve I H A G B F C D Fig. 6 ZK 313 ASME-D/20 14

15 Design continued ZK 313 ASME, angle valve I H A G B F C E Fig. 7 ZK 313 ASME-E/20 15

16 Design continued Key A Groove nut B Hexagon nut 7/8" 9 UNC, ASME C Upper part of valve D Valve body, straight-through design E Valve body, angle design F Name plate G Body bolt 7/8" 9 UNC, ASME B16.5 H Stuffing box screw I Valve spindle with thread M 18 x 1.5, DIN 13 16

17 Installation ZK 313 ASME The control valve ZK 313 ASME is supplied equipped with or without an actuator and ready for installation. If an actuator is mounted on site the technical documentation of the manufacturer of the actuator must be taken into consideration before commissioning the equipment and archived together with the installation manual ZK 313 ASME. Attention Only qualified welders certified e. g. according to DIN EN 287 or ASMW QW-300 WPQ (Welding Performance Qualification) may weld the control valve into pressurized lines. Valve with socket-weld ends 1. Use suitable and approved lifting equipment in order to put the control valve in the mounting position. 2. Before mounting the control valve provide a static support at the place of installation to counterbalance the weight of the actuator. 3. Take direction of flow into consideration. The arrow indicating the flow direction is on the valve body D / E. 4. Consider space required for opening or servicing the valve. When the valve is installed a minimum space of 120 mm is required for removing or mounting the actuator. 5. Remove plastic plugs. They are only used as transit protection. 6. Clean socket-weld ends. 7. Apply approved standard welding process to mount the valve. Valve with butt-weld ends 1. Use suitable and approved lifting equipment in order to put the control valve in the mounting position. 2. Before mounting the control valve provide a static support at the place of installation to counterbalance the weight of the actuator. 3. Take direction of flow into consideration. The arrow indicating the flow direction is on the valve body D / E. 4. Consider space required for opening or servicing the valve. When the valve is installed a minimum space of 120 mm is required for removing or mounting the actuator. 5. Remove plastic plugs. They are only used as transit protection. 6. Clean butt-weld ends. 7. Apply approved standard welding process to mount the valve. Heat treatment of welds After welding the control valve in place the welds require a heat treatment (annealing process for stress relief to DIN EN or QW-406 PWHT (Postweld Heat Treatment)). Materials type F22 and F91 require heat treatment, material type F1 does not require a post weld heat treatment. The heat treatment is restricted to the region of the weld. 17

18 Installation continued Pickling and rinsing The pipe system of a new installation usually has to be pickled and rinsed before it can be commissioned in order to remove dirt and foreign matter accumulated during the mounting procedure. Note that the nozzle inserts of ZK 313 ASME valves must be removed and the valve bodies have to be provided with blind flanges before pipes where control valves ZK 313 ASME are installed can be pickled and rinsed. Please contact the manufacturer or your local dealer if you want to pickle and rinse your installation. Attention The nozzle inserts of the ZK 313 ASME must be removed before pickling and rinsing the system. The valve bodies must be closed off with suitable blind flanges. Installation and deinstallation works must only be performed by the manufacturer or by qualified personnel authorised by the manufacturer. Commissioning ZK 313 ASME Retighten the stuffing box H if leaking occurs. Attention As the stuffing box screw is tightened, the break-away force and the friction force of the valve spindle are increased. The break-away force and the friction force of the valve spindle must not exceed the maximum operating force of the actuator. Excessive tightening of the stuffing box screw impairs the function of the actuator and may cause blocking of the valve spindle. If the valve spindle is blocked, the valve can no longer open, regulate or close. 18

19 Operation ZK 313 ASME Retighten the stuffing box H if leaking occurs. Attention As the stuffing box screw is tightened, the break-away force and the friction force of the valve spindle are increased. The break-away force and the friction force of the valve spindle must not exceed the maximum operating force of the actuator. Excessive tightening of the stuffing box screw impairs the function of the actuator and may cause blocking of the valve spindle. If the valve spindle is blocked, the valve can no longer open, regulate or close. Maintenance Please contact the manufacturer or your local dealer if maintenance is required. Decommissioning Danger Risk of severe burns and scalding over the entire body! Before loosening flanged connections, stuffing box connections or sealing plugs make sure that all connected lines are depressurised (0 bar) and cooled down to room temperature (20 C). Disposal Deinstall the valve and separate the waste materials in accordance with the specifications of the table Materials on page 8. Observe national legal regulations regarding waste disposal. 19

20 GESTRA Agencies all over the world: España GESTRA ESPAÑOLA S.A. Luis Cabrera, E Madrid Tel / Fax / ; aromero@flowserve.com Polska GESTRA POLONIA Spolka z.o.o. Ul. Schuberta 104 PL Gdansk Tel / od 10 Fax / gestra@gestra.pl Great Britain Flowserve Flow Control (UK) Ltd. Burrel Road, Haywards Heath West Sussex RH 16 1TL Tel / Fax / gestraukinfo@flowserve.com Portugal Flowserve Portuguesa, Lda. Av. Dr. Antunes Guimarães, 1159 Porto Tel / Fax / jtavares@flowserve.com Italia Flowserve S.p.A. Flow Control Division Via Prealpi, 30 l Cormano (MI) Tel / Fax / infoitaly@flowserve.com USA Flowserve DALCO Steam Products 2601 Grassland Drive Louisville, KY Tel / , Fax / dgoodwin@flowserve.com GESTRA AG P. O. Box , D Bremen Münchener Str. 77, D Bremen Telephone +49 (0) Fax +49 (0) gestra.ag@flowserve.com Internet /305c 2005 GESTRA AG Bremen Printed in Germany 20

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